BBZP Pneumatic Valve BBZR Long Stroke Pneumatic Valve BBZT Pneumatic Valve

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1 INSTRUCTION MANUAL BBZP Pneumatic Valve BBZR Long Stroke Pneumatic Valve BBZT Pneumatic Valve GB-IST-BBZP-0312

2 Table of Contents 1. Safety signs General safety precautions Receiving/Unpacking/Storage Installation Operation Troubleshooting Cleaning General maintenance Planned maintenance Spare parts ordering Disassembly of valve type BBZP / BBZR...13 Drawings BBZP / BBZR Assembly of valve type BBZP / BBZR Disassembly of valve type BBZP / BBZR divert...18 Drawings BBZP / BBZR divert Assembly of valve type BBZP / BBZR divert Disassembly of BBZT...22 Drawings BBZT Assembly of BBZT Assembly/Disassembly shaft stroke limiter...25 Drawings shaft stroke limiter Parts list Technical data...27 Warranty...28 Disclaimer...28 Foreword This instruction manual is an integral part of the valve delivery. To use the Atex valve model is obligatory to consult the appropriate manual. Always read it carefully before using the valve. Always keep it for future reference. All rights are reserved. It is forbidden to reproduce or transit any part of the instruction manual by any means, either electronic or mechanical, including photo copies, recording or any other memorisation or retrieval system for purposes other than the exclusively personal use by the purchaser without prior written permission by the manufacturer. This instruction manual is expressly intended for use by technicians. Therefore, some information which can easily be inferred by reading the text and examining the illustrations and drawings has not been further specified. The publisher is not responsible for any consequences of incorrect operations by the user. The data and information in this instruction manual are subject to modifications or updates without any further notice or obligations on the part of the manufacturer. (GB-IST-BBZP-0312) 2/28

3 1. Safety/Caution Signs General WARNING sign, which indicates that special instructions MUST be followed to avoid serious personal injuries. General CAUTION sign, which indicates that special instructions MUST be followed to avoid damage of equipment and environment. NOTE! Indicates IMPORTANT information, which improves the understanding of the instructions. 2. General Safety Precautions ALWAYS read the technical data before installation, operation and maintenance. ALWAYS use authorised personal to install, operate and service the valve. The personal should know the valve and the instruction manual thoroughly. ONLY use the valve for the designed purpose. ALWAYS handle heavy valves carefully and use lifting tools where necessary. ALWAYS pay attention to possible loose valve parts when unpacking the delivery. ALWAYS connect air supply carefully and disconnect after use. ALWAYS connect electrical supply carefully and disconnect after use. NEVER touch moving valve parts. NEVER touch a hot valve. ALWAYS handle cleaning agents carefully. NEVER remove a valve from piping or disassemble it when the valve or piping are pressurised. We cannot be held responsible for incorrect installation, operation and maintenance! (GB-IST-BBZP /28

4 3.Receiving/Unpacking/Storage A B ATTENTION! 1. UNPACK AND CHECK VALVE DELIVERY: A. Complete valve B. Instruction manual BBZP BBZP DIVERT BBZR 2. IDENTIFY VALVE TYPE SUPPLIED: BBZP: Pneumatic BBZP: Pneumatic divert BBZR: Pneumatic valve long stroke BBZR: Pneumatic divert valve long stroke BBZR DIVERT 3. LIFTING OF HEAVY VALVE: - Use lifting tool, if necessary. - Fix valve to lifting tool. 4. HANDLING OF LOOSE VALVE PARTS: - Avoid falling loose valve parts. - Assemble and tighten loose parts. Safe valve protection! - Opening - connections - Electrical connections (for Giotto-Top ) Paking material 5. PACKING MATERIAL: - Inspect internal of valve. - Remove material and dispose of according to current directives. 6. INSPECTION/CLAIM: - Inspect valve connections. - Document /verify damage, missing or wrong parts. - Use current claim procedure if necessary. 7. STORAGE/PROTECTION: - Avoid dust, humidity, wet areas, heat and similar. - Avoid vibration. - Min.: - 10 C - Max.: + 50 C (GB-IST-BBZP-0312) 4/28

5 4. Installation Aria Electrical connections Giotto top 1. CONNECTION OF AIR AND EL SUPPLY: - Use authorised personnel to install/connect the valve. - Ensure correct air pressure and quality (see page 26). - Ensure correct electrical supply for Giotto-Top (see Giotto-Top instruction manual). Electrical connections Giotto-Top Aria 2. DISCONNECT SUPPLIES AFTER USE: - Disconnect air supply. - Disconnect electrical supply (for Giotto-Top ). 3. MOVING VALVE PARTS: - Never stick fi ngers into valve ports. - Never touch moving valve shutter/stem. On-off valve Support 4. AVOID VALVE OVERLOADING AND COMPENSATE FOR: - Vibration - Thermal expansion 5. CORRECT FLOW DIRECTION: If possible, have flow against valve closing direction to avoid or minimise water hammer. (GB-IST-BBZP /28

6 4. Installation 6. VALVE CONNECTIONS/UNIONS: - Ensure tight connections between valve and piping. - Remember gaskets and fit correctly. - Tighten unions firmly and carefully. 7. WELDING VALVE BODY INTO PIPING: - Remove inner valve parts. - Weld body carefully into piping. - Assemble valve. - See assembly instructions. BBZP (with Giotto-Top ) Dimenson Valve DN DN40 DN50 DN65 DN80 DN100 DN125 DN150 A (mm) BBZR (with Giotto-Top ) Dimenson Valve A (mm) DN65 DN80 DN100 DN125 DN INSTALLING VALVE INTO PIPING: Ensure sufficient clearance for valve disassembly. (GB-IST-BBZP-0312) 6/28

7 5. Operation Electrical connections Giotto-Top 1. SUPPLYING AIR AND EL TO VALVE: - Use authorised personnel to operate the valve. - Ensure correct air pressure and quality (see page 26). - Ensure correct electrical supply for Giotto-Top (see Giotto-Top instruction manual). Electrical connections Giotto-Top Aria 2. DISCONNECT SUPPLIES AFTER USE: - Disconnect air supply. - Disconnect electrical supply for Giotto-Top 3. MOVING VALVE PARTS: - Never stick fingers into valve ports. - Never touch moving valve shutter/stem. Aria BURNING RISK!! BBZP BBZP DIVERT BBZR BBZR DIVERT 4. ONLY USE VALVE FOR DESIGNED PURPOSE: BBZP: Pneumatic BBZP: Pneumatic divert BBZR: Pneumatic valve long stroke BBZR: Pneumatic divert valve long stroke 5. HOT VALVE/PIPING: - Never touch hot valve or piping, if possible. - Alternatively use protective gloves. Valv. interc. Valv. Deviaz (GB-IST-BBZP /28

8 5. Operation Electrical connections Giotto-Top 6. PRE-USE CHECK VALVE BEFORE OPERATION: - Supply air to the valve. - Supply el to the valve (with Giotto top ). - Open and close the valve several times. - Check that the valve functions operate correctly and smoothly. 6. Troubleshooting 1. TROUBLESHOOTING VALVE: Always study operation and maintenance instructions carefully before troubleshooting. Corrosion risk of stainless steel! Check and replace gaskets! 2. REPLACING WORN VALVE PARTS: - See page 12 for spare parts ordering. External leakage Problem Possible cause Possible remedy Internal leakage withh closed valve, caused by normal wear Worn out gasket Replace gasket External leakage Internal leakage with closed valve occurring earlier than normal wear Difficult opening and closing Too high pressure Too high temperature Aggressive fluids Too many active control Incorrect elastomer type of gaskets Incorrect positioning of actuator Incorrect operation of actuator Dirt in actuator Incorrect positioning of valve body Replace with gasket of different elastomer type Modify operation conditions Replace with gasket of different elastomer type Assemble actuator correctly Change from normally open (NO) to normally closed (NC) or vice versa Check and service actuator Disassemble and reposition valve body (GB-IST-BBZP-0312) 8/28

9 7. Cleaning 1. CLEANING VALVE WITH CLEANING AGENTS: - Use authorised personnel to clean the valve. - Observe concentrations of cleaning agents. - Follow instructions of cleaning agent suppliers. - Always use protective goggles and gloves. Corrosion risk of stainless steel! BURNING RISK!! Damage risk of elastomers!! 2. HOT VALVE/PIPING: - Never touch hot valve or piping, if possible. - Alternatively use protective gloves. 3. HANDLING OF CLEANING AGENTS: - Dose cleaning agents regularly to avoid excessive concentration. - Always rinse carefully with clean water after cleaning. - Check compatibility of valve materials. - Always dispose of cleaning agents according to current directives Example of suggested CIP Step Temperature C Cip product First rinsing Atmosphere Water without chlorine or chlorids Washing 70 Soda (NaOH) at 1% Intermediate washing Atmosphere Water without chlorine or chlorids Washing 70 Nitric acid (HNO3) at 0,5% Final rinsing Atmosphere Water without chlorine or chlorids Recommended claning speed = 2 m/s (GB-IST-BBZP-0312 /28

10 8. General Maintenance Electrical connections Giotto-Top 1. SUPPLYING AIR AND EL TO VALVE: - Use authorised personnel to service the valve. - Ensure correct air electrical supply for Giotto-Top (see Giotto-Top instruction manual). - Ensure correct air pressure and quality (see page 26). - Always dispose of cleaning agents according to current directives. Electrical connections Giotto-Top 2. DISCONNECT SUPPLIES AFTER USE: - Disconnect air supply. - Disconnect electrical supply (for Giotto-Top ). 3. MOVING VALVE PARTS: - Never stick fingers into valve ports. - Never touch moving valve shutter/stem. Atmospheric pressure required! BURNING RISK!! 4. PRESSURISED VALVE/PIPING: Always release fluid pressure from valve and piping before disassembling the valve. 5. HOT VALVE/PIPING: - Never touch hot valve or piping, if possible. - Alternatively use protective gloves. (GB-IST-BBZP-0312) 10/28

11 8. General Maintenance Wash and clean troughly 6. CLEANING OF DEPOSITS: - Wash and clean all valve parts thoroughly before disassembly and assembly! - Pay attention to possible deposits of cleaning agents and other aggressive fluids! - Always use protective goggles and gloves, if necessary. 7. REPLACING WORN VALVE PARTS: - Always use original spare parts. - See page 12 for spare parts ordering.. Planned Maintenance Planned maintenance Valve gaskets Actuator gaskets Preventive Replace after 12 months Replace after 24 months In case of leakage Replace at the end of the day Replace in case of leakage Periodical Check for correct operation and absence of leakage Record all actions taken Check for correct operation and absence of leakage Record all actions taken (GB-IST-BBZP /28

12 10. Spare Parts Ordering NOTE! Please copy this page, fill it out and fax it to below address. À : BARDIANI VALVOLE S.P.A. Ufficio Ricambi Fax: From: Valve type: Serial number: Month/Year of purchase: Shipping instructions: Quantity: Position no.: Description: Quantity: Position no.: Description: Quantity: Position no.: Description: Quantity: Position no.: Description: Quantity: Position no.: Description: (GB-IST-BBZP-0312) 12/28

13 11. Disassembly of BBZP / BBZR Fix the guide bushing (17) through 2 screw M6x10 and supply air to fitting (24). Countherhold! 2. Remove clamp (33) and body (1) Release air pressure to air fitting (24) Unscrew shutter (2). Counterhold the pivot with an Allen wrench Remove shutter ring (14) to the shutter (2) P.T.F.E. SHUTTER: Unscrew shutter nut (28) and remove shutter ring (14) Remove from the cylinder () the cap (50). Remove,from the same, gaskets (156 e 157) and the guide bushing (120) Remove screws (34) and assembly (35) Remove screws M6x10 and guide bushing from the cylinder (17) with a suitable tool. Remove seal rings (277 e 276). (GB-IST-BBZP /28

14 11. Disassembly of BBZP / BBZR VALVE SIZE DN : Remove screw M6x10, remove the washer (7) to the cylinder (), and seal ring (6,1). (GB-IST-BBZP-0312) 14/28

15 11. Disassembly of BBZP / BBZR BBZP (DN ) BBZR ( ) BBZP (DN ) BBZR ( ) P.T.F.E. SHUTTER 12. Assembly of BBZP / BBZR VALVE SIZE DN : 10. Insert seal ring (6, 1) and washer (7) with 2 M6x (GB-IST-BBZP /28

16 12. Assembly of BBZP / BBZR Pre-heat shutter ring (14*) to approx. 80 C to make it softer and insert it in shutter slot (2). Insert the ring in a crosswise manner using a plastic cylindrical tool. 3. PTFE SHUTTER: Assembly the P.T.F.E. seal ring (14) on the shutter (2) and the shutter nut (28) Insert seal rings (276 e 277) on the guide bushing (17) and assembly them on the cylinder () 34 Fix upper guide bushing with two screw M6x Fit assembly (35) to cylinder () with screws (34) COUNTERHOLD! Insert seal rings (156 and 157)* and guide bushing (120)* into the cap (50). Fit the cap on the cylinder (). 7. Screw shutter (2) into cylinder pivot (). Counterhold the pivot with an allen wrench. 8. Supply air to fitting (24). (GB-IST-BBZP-0312) 16/28 *Lubricate elastomers with a product suitable for food contact

17 12. Assembly of BBZP / BBZR Assemble body (1) and assembly (35) with clamp (33). 10. Release air pressure to air fitting (24) and remove 2 M6x10 to allow assembly of the Giotto-Top. (GB-IST-BBZP /28

18 13. Disassembly of BBZP / BBZR divert To fix the washer (17) through 2 screw M6x10 and supply air to fitting (24). Remove clamp (33) between lower body (1) and upper body (42). Remove lower body. 2. Release air pressure to air fitting (24). COUNTERHOLD! a. STANDARD SHUTTER: Remove shutter rings (14) Unscrew shutter (30). Counterhold the pivot with an allen wrench b. P.T.F.E. SHUTTER: Unscrew il dado otturatore (28) from the double shutter stem (212), remove from the double shutter (30) the P.T.F.E. seal ring (14) Remove clamp (33) and upper body (42) from assembly (35). Remove seal ring (108) from upper body (42). 6. Remove from the cylinder() the cap (50). Remove the seal rings (156 e 157) and the guide bushing (120) Remove screws (34) and assembly (35). (GB-IST-BBZP-0312) 18/28

19 13. Disassembly of BBZP / BBZR divert Remove the screw M6x10 and remove the guide bushing (17) from the cylinder with a suitable tool. Remove seal rings (277 and 276).. VALVE SIZE DN : Remove screw M6x10, remove the washer (7) to the cylinder (), and seal ring (6,1). 6 7 (GB-IST-BBZP /28

20 13. Disassembly of BBZP / BBZR divert BBZP divert (DN ) BBZR divert (DN ) BBZP divert (DN ) BBZR divert (DN ) P.T.F.E. SHUTTER 14. Assembly of BBZP / BBZR divert VALVE SIZE DN : 10. Insert seal ring (6, 1) and washer (7) with 2 M6x (GB-IST-BBZP-0312) 20/28

21 14. Assembly of BBZP / BBZR divert Pre-heat shutter ring (14)* to approx. 80 C to make it softer and insert it in shutter slot (2). Insert the ring in a crosswise manner using a plastic cylindrical tool PTFE SHUTTER: Assembly shutter ring (14) and shutter (30) with the stem (212). Assembly shutter ring (14) and shutter nut (28) Insert sela rings (276 e 277) on the guide bushing (17) and assembly them on the cylinder () 34 Fix upper guide bushing with two screw M6x Fit assembly (35) to cylinder () with screws (34) Insert seal rings (156 e 157)* and guide bushing (120)* into the cap (50). Fit the cap on the cylinder (). 7. Insert the clamp (33) between the upper body (42) and the assembly (35). Insert the sealing ring (11) on the lower body (1). (GB-IST-BBZP /28 *Lubricate elastomers with a product suitable for food contact

22 14. Assembly of BBZP / BBZR divert 17 COUNTERHOLD! Screw double shutter (30) into cylinder. Counterhold pivot with an allen wrench.. Insert guide bushing (17) with 2 screws M6x10. Supply air to fitting (24) assemble lower body (1) and upper body (42) with clamp (33). Release air pressure and remove 2 M6x10 to allow assembly of the Giotto-Top. 15. Disassembly of BBZT Disassemble the BBZP according to instructions from fig.1 to fig. 8 at pag Remove elastic thread (177) by rotating plug (173) until the end part of the elastic thread (177) is visible through cylinder slot (). Pull out completely the end part by a pointed tool while rotating plug (173) Remove plug (173) and bushing (175).Unscrew the grub screw (88) and the adjustment pivot (12) from the cylinder (). (GB-IST-BBZP-0312) 22/28

23 15. Disassembly of BBZT Remove piston (66) from the cylinder () and remove seal rings (171, 172) and bushing (204). 5. Remove screws (170) and remove cylinder () and the seal ring (16). Unscrew the upper pivot (23). BBZT (DN ) (GB-IST-BBZP /28

24 16. Assembly of BBZT Assemble the BBZP according to instruction from fig. 7 to fig. 15 from pag. 13 to pag Fit pivot (23) onto cylinder pivot (11). Fit seal ring (16) on the cylinder (). Fit cylinder () on cylinder () with screws (170) Insert seal rings (171, 172)* and bushing (204) into piston (66) and fit it into the cylinder (). 4. Fit adjustement pivot (12) and screw the grub screw (88). Assemble the guide bushing (175) onto the plug (173). assemble the plug (173) onto the cylinder () Fit elastic thread (177) through cylinder slot () into plug (173). Rotate the plug until the elastic thread is completely inserted Adjust the twin-stop stroke by rotating adjustement pivot (12). Fit and tighten threaded dowel (88) to lock the adjustement pivot. (GB-IST-BBZP-0312) 24/28 *Lubricate elastomers with a product suitable for food contact

25 17. Assembly/Disassembly shaft stroke limiter Dismantlement of stroke limiter in inlet Unscrew the screw (25) and remove the mecchanical stop (36) from the upper shaft (23). Assembly of stroke limiter in inlet Screw on the mecchanical stop (36) the screw (25) and the nut (20). Lock the screw (25) on the shaft (23). Adjust the inlet with the mecchanical stop (36) and block it with the nut (20). SHAFT STROKE LIMITER IN INLET Dismantlement of stroke limiter in outlet Unscrew the nut (20) and the screw (25), unscrew the screws (25)and remove the mecchanical stop (36) from the upper shaft (23). Assembly of stroke limiter in outlet Assembly the mecchanical stop (36) on the cilinder () with the screws (25). Screw on the mecchanical stop the screw (25) with the nut (20). Make the regulation with the screw and then block the nut (20). SHAFT STROKE LIMITER IN OUTLET (GB-IST-BBZP /28

26 18. Part List Item Description Item Description 1 Lower body 171 Seal ring 2 Shutter 172 Seal ring 4 Seal ring 173 Stopper cylinder 6 Seal ring 175 Guide bushing Cylinder 177 Snap ring 10 Guide bushing 204 Guide bushing 11 Pivot 20 Nut 14 Seal ring 25 Socket screw 17 Guide bushing 274 Seal ring 23 Upper pivot 275 Seal ring 24 fitting 276 Seal ring 25 Socket screw 277 Seal ring 28 Shutter nut 30 Double shutter 33 Clamp 34 Socket screw 35 Assembly 36 Mecchanical stop 40 Plug 42 Upper body 50 Cap 66 Piston 88 Grub screw Cylinder 120 Guide bushing 12 Pivot 156 Seal ring 157 Seal ring 16 Seal ring 170 Socket screw (GB-IST-BBZP-0312) 26/28

27 1. Technical data Valve technical specifications: Max. working pressure: 10 bar (145 psi) Min. working pressure: Full vacuum Max. product temperature: 140 C (284 F) Min. product temperature: -10 C (14 F) Material in contact with the product: AISI 316L (1.4404) Seals in contact with the product (FDA homologation): EPDM, FKM, HNBR, P.T.F.E. (other seals available upon request). Finish on surfaces in contact with the product: Ra 0.8 µm (other types of surface finish on request). Pneumatic Actuator Specifications: Connectors: 1/8 (BSP) for tube 6x4mm pressure: from 6bar (87psi) to 8bar (116psi) Material: AISI 304L (1.4307) Seal / gasket material: NBR Power supply (Giotto-Top ): See Giotto-Top Instruction manual PED Directive 7/23/EEC, with special reference to Annex III, Module A regarding internal production control as Conformity Assessment Procedure in force valve sizes DN are not included in accordance with Article 3 paragraph 1.3: Valves intended for gases, liquifi ed gases, gases dissolved under pressure, vapours and those liquids whose vapour pressure at the maximum allowable temperature is greater than 0,5 bar above normal atmospheric pressure (1013 mbar) within the following limits - For fl uids in Group 1 with a DN greater than 25 - Valve size DN125 only for fl uids in Group 2 (GB-IST-BBZP /28

28 DISCLAIMER 1. CONTRACTUAL WARRANTIES AND LIABILITY 1.1 Bardiani Valvole S.p.A. warrant that their products are free from defects in design, material and workmanship. Bardiani Valvole S.p.A. shall be liable should any such defects be found within 12 (twelve) months from the date of delivery of the products. 1.2 Any claim regarding defects and/or faults found in the products shall be notified in full and in writing to Bardiani Valvole S.p.A. within 8 (eight) days from the date they were found. Adequate documentation shall be provided as evidence of said defects at the time the claim is filed. 2. LIMITATION IN LIABILITY 2.1 Without prejudice to any statutory right of the Buyer, Bardiani Valvole S.p.A. shall be under no liability in respect of electric components or elastomers that are part of their products. 2.2 The Seller shall be under no liability in respect of defects/faults specified in the following points: - defects and/or faults arising from failure to follow the instructions contained in the Manual of Instruction for the Use and Maintenance of the Product as to the use and storage of the products by the Buyer; - defects and/or faults arising from fair wear and tear of the products or their parts or their components; - defects and/or faults arising from repairs or interventions of the goods carried out by unauthorized or unqualified staff; - defects and/or faults arising from misuse, accidents, negligence and abnormal working conditions caused by the Buyer. 3. WARRANTY 3.1 Bardiani Valvole S.p.A. shall, at their discretion, repair or replace the products that are acknowledged to be defective. 3.2 Should repair or replacement of the product or of its components occur, the parts returned shall become the property of Bardiani Valvole S.p.A. The relevant freight costs involved in the return of the goods or their components shall be entirely met by Bardiani Valvole S.p.A Under no circumstance shall Bardiani Valvole S.p.A. be liable to indemnify immaterial or indirect damages such as damages or consequential loss, whether loss of profit, loss of business, loss of business opportunities, loss of time, loss of goodwill and damage to corporate image, etc. 3.4 The performance of repair or replacement under the above warranty shall not entail any extension of the warranty period of 12 (twelve months), such term being unconditional. 3.5 No distributor, agent or staff to Bardiani Valvole S.p.A. is entitled to make any amendment, extension or addition to the above warranty. WARRANTY 1. All the statements, indications and technical data listed in this document are based on technical tests carried out by Bardiani Valvole S.p.A.. However accurate and reliable, such tests do not reflect all possible circumstances under which the products may be used. It is therefore advisable that the Buyer should always ascertain the suitability of the product in its application. The Buyer will be entirely liable for all risks and damages incurred by said products. Bardiani Valvole S.p.A. are not liable for any accident, loss or damage incurred, whether they be directly or indirectly caused by the use or misuse of the products. No further guarantees other than those stated in this document shall be granted. 2. All our customers are advised to consult our technicians as well as our offices who will supply all information pertaining the technical characteristics of our products. 3. The pictures contained in this document are intended to be general representations. They are not to be intended either legally binding or detailed representations of our products. 4. The data and statements listed in this document only refer to our standard products. They do not apply in any case to any tailor-made products that might have been purchased by the customers. 5. Bardiani Valvole S.p.A. are not liable for any defects or faults resulting from the incorrect installation of their products. Such installation is to be carried out in full compliance with the instructions contained in the Manual of Instructions for the Use and Maintenance of the Product. Bardiani Valvole S.p.A. are not liable for any defects or faults resulting from the incorrect use of their products. 6. Bardiani Valvole S.p.A. are not liable for any defects or faults resulting from the incorrect transportation and/or incorrect storage and/or incorrect maintenance of their products. 7. Bardiani Valvole S.p.A. cannot accept any liability for any faults or damages deriving from mishandling of the products and/or interventions carried out by unqualified personnel. No liability is accepted for damages caused by hits, dents, carelessness, negligence or any other any acts that cannot be considered as construction faults or faults related to the materials used in production. BARDIANI VALVOLE S.P.A. - Via G. di Vittorio 50/ FORNOVO TARO - PR - Tel.: / Fax.: /3408

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